COMPONENT WORK SAMPLE 8 Simulated Assembly MAINTENANCE MANUAL. From 1974 to March 15, 2003

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1 COMPONENT WORK SAMPLE 8 Simulated Assembly MAINTENANCE MANUAL From 1974 to March 15, 2003

2 Copyright 2008 VALPAR International Corporation P.O. Box 5767 Tucson, Arizona All rights reserved. No part of this manual may be reproduced or used in any form or by any means, electronic or mechanical, including photocopying or recording, or by any information storage or retrieval system without permission in writing from the publisher.

3 Table of Contents Section Title Page Introduction 1 1A Checking the Motor and Speed Control 2 Circuit 1974 to December B Checking the Counter and Microswitch to December Trouble Shooting Table to December A Adjusting the Wheel Rotation Speed to December B Speed Control Replacement and Wiring 7 Procedures 1974 to December C Set Screw Tightening Procedures to December D Microswitch Adjustment and Replacement to December E Replacing the Counter to December F Replacing the Kick-Off Angle to December G Adjusting the Motor Tension to December A Checking Motor and Speed Control 12 Circuit 1988 to March 15, B Checking the Counter Microswitch to March 15, Troubleshooting Table to March 15, 2003 i

4 Table of Contents Section Title Page 6A Adjusting the Wheel Rotation Speed to March 15, B Speed Control Replacement to March 15, C Gaining Access to the Inside of the 16 Work Sample 1988 to March 15, D Microswitch Adjustment and Replacement to March 15, E Replacing the Counter to March 15, F Replacing the Kick-Off Angle to March 15, G Adjusting the Motor Tension to March 15, 2003 Drawings 8.1 Work Sample Diagram 8.2 Wiring Diagram 1974 to December Wiring Diagram 1988 to March 15, Wiring Diagram International 8.5 Microswitch Arm Diagram Microswitch Height Diagram ii

5 INTRODUCTION: This VCWS08 Maintenance Manual is written as an aid for our Valpar VCWS08 customers. The VCWS08 Maintenance Manual covers all models of the work sample built from 1974 to the March 15, The models of the VCWS08 can be divided into three categories: 1) models built from 1974 to December 1987, 2) models built from 1988 to the March 15, 2003, 3) models built for international use. Please refer to the sections of this Maintenance Manual that pertain to your VCWS08. Please note that this Maintenance Manual does not include information or wiring diagrams for the VCWS08 speed control. Valpar considers this proprietary information. Any problems that may occur with the speed control must be referred to Customer Service at Valpar International Corporation. The toll-free line is (800) Removal and installation of the speed control is covered in this manual. INTERNATIONAL CUSTOMERS PLEASE NOTE: The work samples built for international use follow the same maintenance instructions as the models built from 1988 to the March 15, The only difference is the wiring. Please refer to the diagram 8.4 for the proper wiring diagram for the international VCWS08. 1

6 1A CHECKING THE MOTOR AND SPEED CONTROL CIRCUIT MODELS BUILT FROM 1974 TO DECEMBER 1987 The most common problems encountered with the VCWS08 are with the speed control. The following steps will be helpful in determining the problem with your VCWSO8. Plug the work sample into a standard wall outlet. Turn the VCWSO8 on with the switch on the left side of the work sample box. If the work sample fails to come on, refer to Part 2A of this troubleshooting guide. After the work sample comes on, allow it to warm up for fifteen minutes. Open the work sample lid. Using the palm of your hand press down on the rotating wheel. If the wheel stops moving and the motor can still be heard refer to part 2C of this troubleshooting guide. The motor may be too loud or there may be a burning smell. This is part of the normal operation of the #8 and in time both problems will correct themselves. Check the wheel speed with a second hand watch. The timing marks on the wheel and on the table should meet every twenty seconds. To adjust your VCWS08 refer to Part 3A of this maintenance manual. If the speed cannot be adjusted, or if after it is adjusted it speeds up or slows down, refer to Part 2B of this manual 1B CHECKING THE COUNTER AND MICROSWITCH MODELS BUILT FROM 1974 TO DECEMBER 1987 While the work sample is running, depress the microswitch arm. The counter should increase by an increment of one each time the microswitch arm is depressed. Refer to Part 2D of this guide if either the counter or microswitch fail to work. Proper microswitch adjustment is critical for the VCWS08 to function properly. Check and adjust according to the instructions in Part 3D of this maintenance manual. 2

7 Section 2 VCWS08 TROUBLE SHOOTING TABLE 1974 TO Dec 1987 PROBLEM POSSIBLE CAUSE SOLUTION 2A VCWS08 WILL NOT RUN 1) BLOWN FUSE REPLACE FUSE 2) DEFECTIVE SPEED CONTROL REPLACE SPEED CONTROL REFER TO PART 3B 3) BREAK IN WIRES REWIRE, REFER TO PART 3B 4) DEFECTIVE MOTOR REFER PROBLEM TO VALPAR CUSTOMER SERVICE 2B VCWS08 RUNS BUT THE 1) SPEED ADJUSTED ADJUST THE WHEEL SPEED SPEED IS ERRATIC OR INCORRECTLY REFER TO SECTION 3A HAS A JERKEY MOTION 2) DEFECTIVE SPEED CONTROL REPLACE SPEED CONTROL REFER TO PART 3B 3) DEFECTIVE LAZY SUSAN REFER PROBLEM TO VALPAR CUSTOMER SERVICE 4) DEFECTIVE MOTOR REFER PROBLEM TO VALPAR CUSTOMER SERVICE 2C MOTOR RUNS BUT THE 1) LOOSE PEDESTAL TIGHTEN SET SCREWS WHEEL DOES NOT SET SCREWS REFER TO PART 3C TURN 2D VCWS08 RUNS BUT 1) IMPROPER MICROSWITCH REALIGN MICROSWITCH COUNTER DOES NOT BEND REFER TO PART 3D WORK 2) MICROSWITCH DEFECTIVE REPLACE MICROSWITCH REFER TO PART 3D 3) COUNTER DEFECTIVE REPLACE COUNTER REFER TO PART 3E 4) BREAK IN WIRES REWIRE THE VCWS08 REFER TO PART 3B 3

8 Section 2 VCWS08 TROUBLE SHOOTING TABLE 1974 TO Dec 1987 PROBLEM POSSIBLE CAUSE SOLUTION 2E PINS JAM BEHIND 1) IMPROPER MICROSWITCH REALIGN MICROSWITCH THE MICROSWITCH BEND REFER TO PART 3D 2) WHEEL SPEED IS ADJUST WHEEL SPEED TO GREAT REFER TO PART 3A 3) INCORRECT TABLE SLOT REFER PROBLEM TO VALPAR CUSTOMER SERVICE 2F PINS AND COLLARS 1) SPEED ADJUSTED ADJUST THE WHEEL SPEED DO NOT SORT OR INCORRECTLY REFER TO SECTION 3A DROP PROPERLY 2) LID OF #8 IS OPEN CHECK FOR OBSTRUCTIONS, CLOSE LID AND SNAP LATCHES 3) KICK-OFF ANGLE IS REPLACE KICK OFF-ANGLE MISSING OR NOT ALIGNED REFER TO PART 3F CORRECTLY 4) DEFECTIVE MOTOR REFER PROBLEM TO VALPAR CUSTOMER SERVICE 2G COLLARS JAM AT THE 1) IMPROPER MICROSWITCH REALIGN MICROSWITCH BACK OF THE WHEEL OR BEND REFER TO PART 3D LAND IN THE CENTER 2) KICK-OFF ANGLE IS REPLACE KICK OFF-ANGLE MISSING OR NOT ALIGNED REFER TO PART 3F CORRECTLY 4

9 Section 2 VCWS08 TROUBLE SHOOTING TABLE 1974 TO Dec 1987 PROBLEM POSSIBLE CAUSE SOLUTION 2H PARTS ARE LOST 1) IMPROPER MICROSWITCH REALIGN MICROSWITCH INSIDE THE BEND REFER TO PART 3D VCWS08 2) CLIENT LOSES PARTS REMOVE PARTS FROM INSIDE REFER TO PART 3C 3) IMPROPER DROP BOARD ANGLE REFER PROBLEM TO VALPAR CUSTOMER SERVICE 4) INCORRECT TABLE SLOT REFER PROBLEM TO VALPAR CUSTOMER SERVICE 2I MOTOR RUNS LOUD OR 1) TENSION SCREW ON THE ADJUST TENSION SCREW A BURNING SMELL MOTOR NEEDS ADJUSTING ON THE MOTOR IS NOTICED REFER TO PART 3G 5

10 3A ADJUSTING THE WHEEL ROTATION SPEED MODELS BUILT FROM 1974 TO DECEMBER 1987 I) Speed Control Models A & B 1974 to June 1985 Speed controls that have a single knob to adjust the speed identify models A & B. With the work sample running, turn the speed control knob completely clockwise. Allow the VCWS08 to warm up at full speed for fifteen minutes before attempting adjustment. Turn the speed control knob counterclockwise and slow the rotation speed. Using the timing marks on the wheel and table, check the rotation speed. Adjust the knob to achieve a twentysecond rotation time. Check the speed after one hour. The time should stay at twenty, plus or minus two seconds. If the timing doesn't stay consistent, the speed control will need to be replaced. Refer to section 3B for replacement procedures. II) Speed Control Model C June 1985 to January 1987 The VCWS08 speed control model C is a black box with a red switch and one large and one small speed adjustment screw on top. This control may by set for two timing intervals, standard and B-kit. Turn the VCWS08 on and set the speed control switch to B-kit and allow the work sample to warm up for fifteen minutes. Use the timing marks on the wheel and table to check the rotation speed. Set the rotation speed to ten seconds with the larger adjustment screw on the right. Turn the screw clockwise to increase, or counterclockwise to decrease the wheel rotation speed. Switch to the standard setting. Set the rotation speed to twenty seconds using the smaller adjustment screw to the left. Check the speed after one hour. The time should stay at twenty, plus or minus two seconds. If the timing doesn't stay consistent, the speed control will need to be replaced. Refer to section 3B for replacement procedures. III) Speed Control Model D January 1987 to March 15, 2003 A red or black switch in the center, a fuse in the upper left corner and two small adjustment screws identifies the model D speed controls. Turn the VCWS08 on and set the speed control switch to B-kit and allow the work sample to warm up for fifteen minutes. Use the timing marks on the wheel and table to check the rotation speed. Set the rotation speed to ten seconds using the B-kit adjustment screw. Switch to standard speed and set it to twenty seconds using the standard screw. The wheel speed will increase with a counterclockwise turn on the adjustment screws. Check the speed after one hour. The standard time should stay at twenty, plus or minus two seconds. If the timing doesn't stay consistent, the speed control will need to be replaced. Refer to section 3B for replacement procedures. 6

11 3B SPEED CONTROL REPLACEMENT AND WIRING PROCEDURES MODELS BUILT FROM 1974 TO DECEMBER 1987 I) Replacing Speed Controls Models A or B with a Model D Step 1: Step 2: Step 3: Step 4: Step 5: Step 6: Step 7: Unplug the VCWS08. Pull off the speed control knob. Remove the two screws on the speed control cover plate Discard the cover plate. Remove the two screws which mount the speed control to the work sample. Gently pull the speed control up until the wire connectors are visible. Untwist the wire connectors and remove the old speed control. Refer to the schematic provided (fig 8.2). Connect the new speed control as follows A. The yellow wire from the speed control to the yellow wire from the motor. B. The blue wire from the speed control to the blue wire from the motor. C. The white wire from the speed control to the white or gray wire and brown wire from the work sample. D. The black or red wire from the speed control to the two black and/or red wires from the work sample. Step 8: Step 9: Mount the new control with the two larger screws provided. Reposition the top and fasten it with the four smaller screws provided. 7

12 II) Replacing Speed Control Models C or D with a Model D Step 1: Step 2: Step 3: Step 4: Step 5: Step 6: Step 7: Unplug the VCWS08. The top of the old speed control is attached with four rivets that must be removed. To do this, use a 1/8-inch drill bit, or place a screwdriver under the rivet heads and break them off. Remove the speed control top by pulling up on the red or black switch. Remove the two screws inside the speed control that mount it to the work sample. Set the screws aside. Gently pull the speed control up until the wire connectors are visible. Untwist the four wire connectors and remove the old speed control. Save the connectors for the next step. Refer to the schematic provided (fig 8.2). Connect the new speed control as follows: A. The yellow wire from the speed control to the yellow wire from the motor. B. The blue wire from the speed control to the blue wire from the motor. C. The white wire from the speed control to the white or gray wire and brown wire from the work sample. D. The black or red wire from the speed control to the two black and/or red wires from the work sample. Step 8: Mount the new control with the screws that were set aside in Step 4. Step 9: Reposition the top and fasten it with the screws provided. 8

13 3C SET SCREW TIGHTENING PROCEDURES MODELS BUILT FROM 1974 TO DECEMBER 1987 I) For Models from 1974 to 1985 Step 1: Step 2: Step 3: Step 4: Step 5: Step 6: Step 7: Unplug the VCWS08. Open lid by releasing outside latches. Remove the two Phillips screws located on either side of the VCWS08 box just below the latches. Remove the two Phillips screws located on the front face of the work sample box. Remove the two small Phillips screws located in the front corner of the slanted drop board. Remove the drop board from the work sample box. To do this lift up slightly on the table and pull up and forward using the angle divider mounted to the drop board. Now the two setscrews on the pedestal are accessible. Tighten the setscrews with a standard 1/8" Allen wrench. Reverse the above steps to reassemble. Make sure all the screws line up with their original holes. II) For Models from 1985 To 1988 Step 1: Step 2: Step 3: Step 4: Unplug the VCWSO8. Open lid by releasing outside latches. Remove only the end of the lid support that is attached to the box ( 1 screw only). Lower the lid over the back of the box. (Caution: Support the lid to avoid overextending the hinge.) Remove the microswitch bracket, by removing the two screws, and set it aside. It is not necessary to disconnect the wires. Remove the two Phillips head screws from behind the black retaining ring. Remove the two Phillips screws located on each side of the work sample box just below the latches. The table is now loose. 9

14 Step 5: Step 6: Step 7: Lift up and forward on the table until the motor mount rests on the drop board. You will have access to the pedestal set screws. If you have a model with a motor mount box (June 1985 to Sept 1987) use the 1/2" diameter hole on the left side of the motor mount box for access. Tighten both set screws with the 1/8" by 10" Allen wrench provided. Be sure the pedestal rests tightly against the motor housing. Reverse the above steps to reassemble. Make sure all the screws line up with their original holes. 3D MICROSWITCH ADJUSTMENT AND REPLACEMENT MODELS BUILT FROM 1974 TO DECEMBER 1987 Note: Be sure the work sample is unplugged before proceeding. I) Microswitch Adjustment The curve of the microswitch arm is critical for the work sample to function properly. Use Figure 8.5 as a template to adjust the curve. Bend the microswitch arm as needed to match the figure. Adjust the height of the microswitch as shown in Figure 8.6. The top of the collar assembly should meet the top of the microswitch arm. Do not make this adjustment by bending the microswitch arm. Loosen the mounting screws and reposition the aluminum bracket to make the adjustment. When the microswitch is in the correct position, tighten the mounting screws. II) Microswitch Replacement Remove the old microswitch from the aluminum bracket. Loosen the screws on the back of the microswitch where the wires are connected. Connect the wires to the new microswitch. One wire is connected to the common screw and the other is connected to the open screw. The screws are marked on the back of the microswitch. Remount the microswitch and adjust using the above procedure. 10

15 3E Replacing the Counter The table must be removed for access to the counter. Refer to section 3C II steps, 1 through 4, for the procedures to remove the table. The counter is glued to an angle block inside the work sample box. Remove the counter by tapping it lightly with a hammer until the glue breaks. Remove the wires from the old counter and slide it out of the box. The new counter comes with a mounting plate and screws. No gluing will be necessary. Slide the new counter into the box and connect the wires. Mount the counter using the screws provided. Reassemble the work sample by reversing the steps from part 3C. 3F REPLACING THE KICK-OFF ANGLE MODELS BUILT FROM 1974 TO DECEMBER 1987 If the assembly parts are not sorting correctly, or if they jam, or land on the middle of the wheel, the kick-off angle needs to be replaced. Open the work sample lid. The proper location for the kick off angle is one-half inch from the bottom of the lid retainer ring (the retainer ring is the curved piece on the inside of the lid). Mount the new angle under the bottom center of the ring with the screws facing to the right. Remove all other similar angles that might be on the work sample lid. 3G ADJUSTING THE MOTOR TENSION MODELS BUILT FROM 1974 TO DECEMBER 1987 During normal operation the VCWS08 might have a burning smell. The motor will also be noisy. These conditions are common and are nothing to worry about. If the motor is too loud, the tension screw on the motor may be adjusted. Refer to part 3C II steps 1 through 4 to remove table. This will allow access to the motor. Located in the back of the motor is a setscrew with an adjusting nut. Use a 1/2" wrench to loosen the nut. While the work sample is running, turn the setscrew until the motor is quieter. Note: Some motors will be quieter when the screw is loosened, and some will be quieter when the screw is tightened. When the motor is running more smoothly, tighten the nut around the setscrew. Reverse the steps in part 3C to reassemble the work sample. 11

16 4A CHECKING THE MOTOR AND SPEED CONTROL CIRCUIT MODELS BUILT FROM 1988 TO MARCH 15, 2003 The most common problems encountered with the VCWS08 are with the speed control. The following steps will be helpful in determining the problem with your VCWS08. Plug the work sample into a standard wall outlet. Turn the VCWS08 on with the switch on the left side of the work sample box. If the work sample fails to come on, refer to Part 5A of this troubleshooting guide. After the work sample comes on, allow it to warm up for fifteen minutes. Open the work sample lid. The motor may be too loud or there may be a burning smell. This is part of the normal operation of the VCWS08 and in time both problems will correct themselves. Check the wheel speed with a second hand watch. The timing marks on the wheel and on the table should meet every twenty seconds. To adjust your VCWS08 refer to Part 6A of this maintenance manual. If the speed cannot be adjusted, or if after it is adjusted it wanders, refer to Part 5B of this manual. 4B CHECKING THE COUNTER AND MICROSWITCH MODELS BUILT FROM 1988 TO MARCH 15, 2003 While the work sample is running, depress the microswitch arm. The counter should increase by an increment of one each time the microswitch arm is depressed. Refer to Part 5D of this guide if either the counter or microswitch fail to work. Proper microswitch adjustment is critical for the VCWS08 to function properly. Check and adjust according to the instructions in Part 6D of this maintenance manual. 12

17 Section 5 VCWS08 TROUBLE SHOOTING TABLE 1988 TO MARCH 15, 2003 PROBLEM POSSIBLE CAUSE SOLUTION 5A VCWS08 WILL NOT RUN 1) BLOWN FUSE REPLACE FUSE 2) DEFECTIVE SPEED CONTROL REPLACE SPEED CONTROL REFER TO PART 6B 3) BREAK IN WIRES REWIRE, REFER TO DIAGRAMS 8.3 OR 8.4 4) DEFECTIVE MOTOR REFER PROBLEM TO VALPAR CUSTOMER SERVICE 5B VCWS08 RUNS BUT THE 1) SPEED ADJUSTED ADJUST THE WHEEL SPEED SPEED IS ERRATIC, OR INCORRECTLY REFER TO SECTION 6A HAS A JERKEY MOTION 2) DEFECTIVE SPEED CONTROL REPLACE SPEED CONTROL REFER TO PART 6B 3) DEFECTIVE LAZY SUSAN REFER PROBLEM TO VALPAR CUSTOMER SERVICE 4) DEFECTIVE MOTOR REFER PROBLEM TO VALPAR CUSTOMER SERVICE 5C VCWS08 RUNS BUT 1) IMPROPER MICROSWITCH REALIGN MICROSWITCH DOES NOT COUNT BEND REFER TO PART 6D 2) MICROSWITCH DEFECTIVE REPLACE MICROSWITCH REFER TO PART 6D 3) COUNTER DEFECTIVE REPLACE COUNTER REFER TO PART 6E 4) BREAK IN WIRES REWIRE, REFER TO DIAGRAMS 8.3 OR 8.4 5D PINS JAM BEHIND 1) IMPROPER MICROSWITCH REALIGN MICROSWITCH THE MICROSWITCH BEND REFER TO PART 6D 2) WHEEL SPEED IS ADJUST WHEEL SPEED TO GREAT REFER TO PART 6A 13

18 Section 5 VCWS08 TROUBLE SHOOTING TABLE 1988 TO MARCH 15, 2003 PROBLEM POSSIBLE CAUSE SOLUTION 5E PINS AND COLLARS 1) SPEED ADJUSTED ADJUST THE WHEEL SPEED DO NOT SORT OR INCORRECTLY REFER TO SECTION 6A DROP PROPERLY 2) LID OF #8 IS OPEN CHECK FOR OBSTRUCTIONS, CLOSE LID AND SNAP LATCHES 3) KICK-OFF ANGLE IS REPLACE KICK OFF MISSING OR NOT ALIGNED ANGLE REFER TO PART 6F CORRECTLY 4) DEFECTIVE MOTOR REFER PROBLEM TO VALPAR CUSTOMER SERVICE 5F COLLARS JAM AT THE 1) IMPROPER MICROSWITCH REALIGN MICROSWITCH BACK OF THE WHEEL OR BEND REFER TO PART 6D LAND IN THE CENTER 2) KICK-OFF ANGLE IS REPLACE KICK OFF-ANGLE MISSING OR NOT ALIGNED REFER TO PART 6F CORRECTLY 5G PARTS ARE LOST 1) IMPROPER MICROSWITCH REALIGN MICROSWITCH INSIDE THE BEND REFER TO PART 6D VCWS08 2) CLIENT LOSES PARTS REMOVE PARTS FROM INSIDE REFER TO PART 6C 3) IMPROPER DROP BOARD ANGLE REFER PROBLEM TO VALPAR CUSTOMER SERVICE 2I MOTOR RUNS LOUD OR 1) TENSION SCREW ON THE ADJUST TENSION SCREW A BURNING SMELL MOTOR NEEDS ADJUSTING ON THE MOTOR IS NOTICED REFER TO PART 6G 14

19 6A ADJUSTING THE WHEEL ROTATION SPEED MODELS BUILT FROM 1988 TO MARCH 15, 2003 Turn the VCWS08 on with the switch on the left side of the work sample. Open the work sample lid and set the speed control to B-kit. Allow the VCWS08 to warm up for fifteen minutes. Use a stopwatch to check the wheel rotation speed. The timing mark on the wheel should pass the timing mark on the table every ten seconds. Use the B-Kit adjustment screw to set the speed to ten seconds. Switch to standard speed and use the standard screw to set the speed to twenty seconds. The wheel speed will increase with a counterclockwise turn on the adjustment screws. Check the speed after one hour. The standard time should stay at twenty, plus or minus two seconds. If the timing doesn't stay consistent, the speed control will need to be replaced. Refer to section 6B for replacement procedures. 6B SPEED CONTROL REPLACEMENT MODELS BUILT FROM 1988 TO MARCH 15, 2003 Step 1: Step 2: Step 3: Step 4: Step 5: Step 6: Step 7: Unplug the VCWS08. Open the VCWS08 lid. Remove the four corner screws on top of the speed control. Set the screws aside. Lift up gently on the red or black switch to remove the speed control top. Remove the two screws inside the speed control that mount it to the work sample. Set the screws aside. Gently pull the speed control up until the wire connecting harness is visible. Unplug the speed control from the wiring harness. Plug in the new speed control. Step 8: Mount the new control with the screws that were set-aside in Step 4. Step 9: Reposition the top and fasten it with the screws from Step 2. 15

20 6C GAINING ACCESS TO THE INSIDE OF THE WORK SAMPLE MODELS BUILT FROM 1988 TO MARCH 15, 2003 Note: It is very important to follow these procedures. Failure to do so will result in damage to the work sample. If the wheel is removed from the table it will have to be shipped to Valpar for realignment. Step 1: Step 2: Step 3: Step 4: Step 5: Step 6: Unplug the VCWS08. Open the lid by releasing the outside latches. Remove only the end of the lid support that is attached to the box (one screw only). Lower the lid over the back of the box. (Caution: Support the lid to avoid overextending the hinge.) Remove the microswitch bracket by removing the two screws, and set it aside. It is not necessary to disconnect the wires. Remove the five Phillips head screws located behind the black retaining ring. Lift up on the retaining ring until you have access to the speed control plug. Unplug the speed control and place the retaining ring out of your way. Remove the two Phillips head screws located on each side of the work sample box just below the latches. The table is now loose. Lift up and forward on the table until the motor mount rests on the drop board. Unplug the motor from the wiring harness. The table and the motor may now be removed from the work sample. Reverse the above steps to reassemble the work sample. Make sure all screws line up with their original holes. 16

21 6D MICROSWITCH ADJUSTMENT AND REPLACEMENT MODELS BUILT FROM 1988 TO MARCH 15, 2003 Note: Be sure the work sample is unplugged before proceeding. I) Microswitch Adjustment The curve of the microswitch arm is critical for the work sample to function properly. Use Figure 8.5 as a template to adjust the curve. Bend the microswitch arm as needed to match the figure. Adjust the height of the microswitch as shown in Figure 8.6. The top of the collar assembly should meet the top of the microswitch arm. Do not make this adjustment by bending the microswitch arm. Loosen the mounting screws and reposition the aluminum bracket to make the adjustment. When the microswitch is in the correct position, tighten the mounting screws. II) Microswitch Replacement Remove the old microswitch from the aluminum bracket. Loosen the screws on the back of the microswitch where the wires are connected. Connect the wires to the new microswitch. One wire is connected to the common screw and the other is connected to the open screw. The screws are marked on the back of the microswitch. Remount the microswitch and adjust it using the above procedure. 6E 6F REPLACING THE COUNTER MODELS BUILT FROM 1988 TO MARCH 15, 2003 Remove the two mounting screws from the face of the counter. Gently pull the counter out from the side of the work sample until the wires are exposed. Unplug the wires from the old counter. Be careful not to let the wires fall inside the work sample. Plug the wires into the new counter. Mount the counter to the work sample using the same two screws. REPLACING THE KICK-OFF ANGLE MODELS BUILT FROM 1988 TO MARCH 15, 2003 If the assembly parts are not sorting correctly, or if they jam or land on the middle of the wheel, the kick off angle needs to be replaced. Open the work sample lid. The proper location for the kick-off angle is one half inch from the bottom of the lid retainer ring (the retainer ring is the curved piece on the inside of the lid). Mount the new angle under the bottom center of the ring with the screws facing to the right. 17

22 6G ADJUSTING THE MOTOR TENSION MODELS BUILT FROM 1988 TO MARCH 15, 2003 During normal operation the VCWS08 might have a burning smell. The motor will also be noisy. These conditions are common and are nothing to worry about. If the motor is too loud, the tension screw on the motor may be adjusted. Refer to part 6C steps to remove the table. This will allow access to the motor. Located in the back of the motor is a setscrew with an adjusting nut. Use a 1/2" wrench to loosen the nut. While the work sample is running, turn the setscrew until the motor is quieter. Note: Some motors will be quieter when the screw is loosened, and some will be quieter when the screw is tightened. When the motor is running more smoothly, tighten the nut around the set screw. Reverse the steps in part 6C to reassemble the work sample. 18

23 Figure 8.1 Work Sample Diagram 19

24 Figure 8.2 Wiring Diagram 1974 to December

25 Figure 8.3 Wiring Diagram 1988 to March 15, 2003 CONNECTIONS: Solder Connection 58 Fork Term. (17H06) 59 Ring Term.(S) (17H07) 60 Slip Term. (L) 61 Slip Term. (S) 21 Ring Term. (L) (17H08) CONNECTIONS: Solder Connection 58 Fork Term. (17H06) 59 Ring Term.(S) (17H07) 60 Slip Term. (L) 61 Slip Term. (S) 21 Ring Term. (L) (17H08) COLORS (WIRES): BK BLACK W WHITE G GREEN BR BROWN BR BROWN (RIBBED) Y YELLOW BL BLUE DkG DARK GREEN GR GRAY GR GRAY (RIBBED) G/Y GREEN WITH YELLOW STRIPE 21

26 Wire Harness and Color Cole NO. COLOR DESCRIPTION 1 BK, W, G Power Cord (2 Sheath Rem.) 58 2 Y, BL Pigtails on Motor (Trim 9 ) 3 BK Pigtails on Trans. (Trim 2 ) 58 4 DkG Pigtails On Trans. (Trim 4 ) 5 G G G G G BK BK BK W BR BR BR BR BR BL Y BK (For Figure 8.3) 22

27 23 Figure 8.4

28 Color Code (for figure 8.4) NO. COLOR DESCRIPTION 1 BR, BL, G/Y Power Cord (2 Sheath Rem.) 58 2 Y, BL Pigtails on Motor (Trim 9 ) 3 BK Pigtails on Trans. (Trim 2 ) 58 4 DkG Pigtails On Trans. (Trim 4 ) 5 G G G G G BK (See 24) BK BK W BR BR BR BR BR BL Y BK G W BK GR, GR Cord on Trans (P) (Cut 11 ) BR, GR, G Cord on Trans (S) (Cut 5 ) 58 24

29 Figure 8.5 Figure

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